PLC Apppppp

Programmable Logic
Controller (PLC) Guide
PLC Training Systems

Model 3240-A
PLC: Allen-Bradley MicroLogix 1100
Used by DeVry University for their PLC course
Built-in 10/100 Mbps Ethernet/IP port for peer-to-peer
messaging
Eight fault switches
Embedded Web server and LCD screen
Online editing functionality
Digital and Analog I/Os; Digital (24 VDC): 10 inputs (four
40kHz high-speed), 6 outputs (two 40 kHz high-speed);
Analog (0 - 10 VDC): 2 inputs
PID Capability
Five push-button and five toggle switches
24 VDC built-in power supply
Easy expansion using rackless I/O modules (Analog
Expansion Module 3244-A)
Onboard traffic light simulator
Compatibility with MicroLogix and SLC instruction set
Requires the RSLogix 500 programming software (Model 3245-A)
For programming, an Ethernet cable is included with the trainer, but a serial cable (Model 3246-4) can also
be ordered
Includes curriculum
Model 3240-B
PLC: Siemens ET200S IM151-8
8 inputs (24 VDC only) and 12 outputs (24 VDC)
PID Capability
Easy expansion using rackless I/O modules (analog expansion
module 3244-B)
Four push-buttons and four toggle switches
Based on Siemens S7-300 technology (IM151-8 CPU)
Requires the Step 7 programming software (Model 5939)
For programming, an Ethernet cable is included with the trainer
Includes Siemens Resource Curriculum CD-ROM
No Lab-Volt curriculum included

Model 3240-C
PLC: Siemens ET200S IM151-8
Rugged suitcase for easy transportation and storage
Includes storage compartment for cables and accessories
8 inputs (24 VDC only) and 12 outputs (24 VDC)
PID Capability
Easy expansion using rackless I/O modules (analog expansion
module 3244-C)
Four push-buttons and four toggle switches
Based on Siemens S7-300 technology (IM151-8 CPU)
Requires the Step 7 programming software (Model 5939)
For programming, an Ethernet cable is included with the trainer
Includes Siemens Resource Curriculum CD-ROM
Model 3240-4
Rugged suitcase for easy transportation and storage. Also include a storage
compartment for cables and accessories
Digital I/Os; 14 inputs (24 VDC),10 Outputs (Relay 24 VDC)
Twelve fault switches
PID Capability
Easy expansion using rackless I/O modules (Analog expansion module 3244-4)
Three push-button and four toggle switches
Programming serial cable is included with the model (with a serial-to-USB
converter also included)
Includes curriculum

Model 3240-3
12 inputs (24 VDC only) and 12 outputs (24 VDC relay outputs)
PID Capability
Easy expansion using rackless I/O modules (Expansion module
3244-3
Six push-buttons and six toggle switches
Compatibility with MicroLogix and SLC instructions set
Programming serial cable is included with the model (with a
serial-to-USB converter also included)
Includes curriculum
Model 3270-4
Compact design
Digital I/Os: 10 inputs (24 VDC), 6 outputs (Relay 24 VDC)
No possible expansion
No PID Control
Form-factor compatible with the Hydraulic/Pneumatic perforated
work surfaces and the 8036 Industrial Controls workstations
and programming cable (3246-4)
Used with Hydraulic and Pneumatic Systems, Models 6080 and
6081; includes curriculum

Model 3270-6
PLC: Siemens SIMATIC S7-222
Compact design
Digital I/Os: 8 inputs (24 VDC) 6 outputs (Transistor - 24
VDC)
Requires a 24 VDC power supply (Model 6360)
Fully configurable, integrated PID controller
Form-factor compatible with the Hydraulic/Pneumatic perforated work surfaces and the 8036 Industrial Controls workstations
Requires Step7 Micro/Win programming software (Model 32453) and programming cable (Model 3246-3)
Used with Hydraulic and Pneumatic Systems, Models 6080
and 6081; includes curriculum
Various PLC Software Screen Images

The PLCs on these two pages were designed specifically for the Flexible Manufacturing System, Models 5901-30, -40,
-50, and -60 or the Industrial Controls Training System, Model 8036. These PLCs can also be used for PLC training.
Model 5930
PLC: Allen-Bradley CompactLogix L32E
Digital I/Os: 16 inputs (24 VDC), 16 outputs (Relay - 24 VDC)
Built-in 24 VDC power supply
PID Capability
Easy expansion using rackless I/O modules
Can be programmed using four languages: Relay ladder,
structured text, sequential function chart, and function block
diagram
Supports three types of network communications: DF1 Full
Duplex Serial Link (RS-232-C), Ethernet/IP, and DeviceNet
Requires RSLogix 5000 Lite Edition programming software (Model
5935) and a standard RJ45 cable (included)
Model 5930-A
PLC: Allen-Bradley CompactLogix L43
Digital I/Os: 16 inputs (24 VDC), 16 outputs (24 VDC)
PID Capability
Integrated Motion Control with SERCOS interface (Interface
included with Model 5929-A from the Flexible Manufacturing
System)
Can be programmed using four languages: Relay ladder,
structured text, sequential function chart, and function block
diagram
Supports four types of network communications: DF1 Full
Duplex Serial Link, Ethernet/IP, SERCOS, and DeviceNet.
Requires RSLogix 5000 Lite Edition programming software
(Model 5935)
Standard Ethernet cable included for programming
Used with the 5901-3/-4 Flexible Manufacturing System
curriculum

Model 5930-B
PLC: Siemens S7-315T
Digital I/Os: 16 inputs (24 VDC), 16 outputs (24 VDC)
PID Capability
Siemens Technological CPU
Can be programmed using several languages
Supports three types of network communications: DF1 Full
Duplex Serial Link, PROFINET, and PROFIBUS.
Requires Step 7 programming software (Model 5939)
Standard Ethernet cable included for programming
Used with the 5901-5/-6) Flexible Manufacturing System
curriculum
Model 3128
PLC: Moeller EASY512
Compact design
Digital I/Os: 8 inputs (24 VDC), 4 outputs (Relay - 24
VDC)
LCD Display
Two of the eight digital inputs can be configured as 0-10
VDC analog inputs
Requires a 24 VDC power supply (Model 3139)
Form-factor compatible with the 8036 Industrial Controls
workstations
Includes EASY-SOFT Basic programming software and programming cable
Used with 8036 Industrial Controls System; includes
curriculum
PLC Applications
Model 5901-3/-4 Flexible Manufacturing System
The Lab-Volt Flexible Manufacturing System (FMS) consists of two subsystems: Models 5901-3 and 5901-4.
The Flexible Manufacturing System, Model 5901-3, allows students to familiarize themselves with manufacturing applications commonly encountered in modern facilities. The modular construction of the FMS permits
a wide variety of setups allowing students to reproduce the operation of an industrial production line. Students will be introduced to programmable logic controller (PLC) programming, sensors, DeviceNet network
configuration, quality control issues, and troubleshooting of FMS through a series of carefully designed exercises. The Flexible Manufacturing System (Advanced Applications), Model 5901-4, is an add-on to the Model
5901-3 and provides the latest manufacturing technology equipment to create more sophisticated applications. Banana jacks and terminal blocks are available on each module.
FMS Features
Compatible PLCs: Refer to chart on pages 14-15
Simulates the operation of a production line
Operation simulation of a production line in a
classroom laboratory
Cognex In-Sight Vision System
Servo Control
Automatic and Storage Retrieval Unit (optional
Model 5940)
Several communication networks (Ethernet IP,

DeviceNet, Serial, SERCOS)
Pneumatic-activated devices
Variety of Sensors
Human-Machine Interface
Fault-insertion capabilities
Includes job sheets
PLC Applications
Model 5901-5/-6 Flexible Manufacturing System
The Flexible Manufacturing System, Models 5901-5 and 5901-6, is the Siemens version of the Flexible
Manufacturing System, Model 5901. The systems main new feature is the integration of the motion instructions and settings directly in the S7-300 PLC. The Lab-Volt Flexible Manufacturing System (FMS) consists
of two subsystems (Models 5901-5 and 5901-6). The Flexible Manufacturing System, Model 5901-5, allows
students to familiarize themselves with manufacturing applications commonly encountered in modern facilities. The modular construction of the FMS permits a wide variety of setups allowing students to reproduce
the operation of an industrial production line. Students will be introduced to programmable logic controller
(PLC), sensors, PROFIBUS network configuration, quality control issues, and troubleshooting of FMS through
a series of carefully designed exercises. The Flexible Manufacturing System (Advanced Applications), Model
5901-6, is an add-on to the Model 5901-5 and provides the latest manufacturing technology equipment to
create more sophisticated applications. Banana jacks and terminal blocks are available on each module.
FMS Features
Operation simulation of a production line in a classroom laboratory
PROFIBUS Micromaster AC Drive
Siemens S7-300 PLC
Cognex In-Sight Vision System
Servo Control
Automatic and Storage Retrieval Unit (optional
Model 5940)
PLC compatible with PROFINET and PROFIBUS networking

Current industry software for PLC programming,
HMI configuration, and PROFINET networking
Pneumatic-activated devices
Variety of Sensors
Human-Machine Interface
Fault-insertion capabilities
PLC Applications
Model 8075-1 Traffic Light System
Shown with optional equipment

(optional)
A well-known classic training system
Traffic light synchronization
N-S/E-W traffic control with pedestrian crossing
Fault insertion
Another unit can be added to create a full, fourdirections traffic light
LEDs (long life)
Flow management with proximity detectors
Includes job sheets
Ten 24 VDC control inputs
Model 8075-2 Electro-Pneumatic System

Two double-acting cylinders
Two reed switches and one mechanical limit
switch for PLC feedback
Perforated work surface
Control valve station featuring single- and double-
10
solenoid valves (Accepts three 24 VDC control

signals from PLC)
Applications: Stamping, hold and punch, filling
process, etc.
Fault insertion
Includes job sheets
PLC Applications
Model 8075-3 Electro-Mechanical System (DC Motor)

Perforated base to accommodate optional sensors
Explores drives and lead screw positioning

systems used in motion processes
Fault insertion
Industrial 1800 RPM, 90 VDC motor
Accepts three 24 VDC control signals from PLC
Two magnetic limit switches for PLC feedback

Bi-directional, regenerative DC drive
Optional 100 ppr Optical Encoder

Includes job sheets
Model 8075-4 Electro-Mechanical System (Stepper Motor)

Two magnetic limit switches for PLC feedback
High-torque Stepper motor
DC power supply
Stepper motor drive programmed by computer

using manufacturer software
Perforated base to accommodate optional sensors
Programmable Stepper motor drive
Optional 100 PPR Optical Encoder
Motion sequences triggered by the PLC I/Os

Lead screw mechanism
Fault insertion
Accepts eight 24 VDC control signals from PLC
Includes job sheets
11
PLC Applications
Model 8075-5 Wind Turbine System
System comprised of a Lab-Volt Nacelle
Simulator Model 3297 and a Wind Generator
Model 3213
Small blower for generating air flow
Nacelle equipped with DC motor and Mechanical
clutch
Two limit switches with NO and NC contacts
Analog position sensor measures wind direction
(0 - 10 V)
Frequency variable pulse train signal measures
wind speed (24 VDC)
Requires external 24 V Power Supply
Accepts two 24 VDC control signals from PLC for
motor operation
Includes job sheets
Model 8075-6 Level Process Control System

Compatible PLCs: Refer to chart on pages
14-15
Submersible variable speed pump
Level process column
Electronic level process Interface
Float switch
Capacitive level switch
Magnetic level switch
Solenoid valve
Manual valve
Optional analog level sensor
Self-regulating process allows a variety of
PLC control schemes
Explore batch and PID control (dependent on
PLC specifications)
12
Includes job sheets
PLC Applications
Model 8075-7 Bottling Process System

Double-acting cylinder
Film canister capping process
DC power supply
Compact application combines pneumatics,

motion control, and PLC sequencing
Perforated work surface
Two high-torque Stepper motors

Dual Stepper motor drive
Inductive proximity switch
Mechanical switch
Dual Stepper motor drive can be used as a Step/

Dir or Jog/Dir drive
Optional accessories allow containers to be filled
with liquid during process
Includes job sheets
Single solenoid directional valve
13
Easy Reference Guide PLC Compatibility

Model
System
PLC Applications
Compatible Lab-Volt Models/ PLCs
5901-3/-4
Flexible Manufacturing System
Model 5930-A: Allen-Bradley CompactLogix L43
5901-5/-6
Flexible Manufacturing System
Model 5930-B: Siemens SIMATIC S7-315T
6082-5
Hydraulics and Pneumatics

Applications - Allen-Bradley PLC
Model 3270-4: Allen-Bradley MicroLogix 1000
6082-7
Hydraulics and Pneumatics

Applications -Siemens PLC
Model 3270-6: Siemens SIMATIC S7-222
Model 3240-B: Siemens ET200S

Model 3240-C: Siemens ET200S
8075-1
Traffic Lights System

Other PLCs offer partial curriculum coverage.
Model 3240-A: Allen-Bradley MicroLogix 1100

8075-2
Electro-Pneumatic System


8075-3
Electro-Mechanical System

14
Easy Reference Guide - PLC Compatibility

Model
System
PLC Applications
Compatible Lab-Volt Models/ PLCs
8075-4
Electro-Mechanical System


Model 3240-B & 3244-B: Siemens ET200S and
Analog Expansion Kit
8075-5
Wind Turbine Application System
Model 3240-C & 3244-C: Siemens ET200S and

Model 3240-4 & 3244-4: Allen-Bradley MicroLogix
1200 and Analog Expansion Kit
Model 3240-B & 3244-B: Siemens ET200S and

Model 3240-C & 3244-C: Siemens ET200S and
8075-6
Level Process Control System

Model 3240-A & 3244-A: Allen-Bradley MicroLogix
8075-7
Bottling Application System

15
Optional Equipment
Lab-Volt Optional Equipment
Model
Image
Description
3139
3139
6360
6360
3201-3204
3205
16
DC Power Supply: Some Lab-Volt PLCs do not feature built-in DC power

supplies. However, these two PLCs are generally components of systems
that already include the required 24 VDC supplies. Model 3139 is part of
the 8036 Industrial Controls system. Model 6360 is part of the Hydraulic
and Pneumatic Systems, Models 6080 and 6081.
3201: Push-Buttons/Lights - Features two NO and one NC momentary
push-button, and three LED indicator lights. Can simulate a Start/Pause/
Stop station with indicator lights.
3202: Toggle Switches/Lights - Features three toggle switches and
three LED Indicator Lights.
3203: Rotary Switch - Features two rotary switches with NO and NC
contacts.
3204: Emergency Switch - Features one emergency switch with two NO
contacts (one for low voltage and the other for line voltage)
Wiring Module - This multi-purpose module allows easy interface between
customers existing PLCs and 2 mm leads and jacks used with the LabVolt PLC Applications. This model can also be used to practice wiring skills
using the terminal blocks.
3210
Optical Encoder - This model is an optional add-on to the ElectroMechanical applications. It provides position feedback (100 PPR) with
signal levels compatible with the PLC 24 VDC inputs.
3214
Level Sensor - This model is an optional add-on to the Process Control

system (8075-60). It provides water level feedback (0-5 VDC or 4-20 mA)
through the Level Process Interface.
5924
Signal Tower: The Signal Tower consists of three lights providing

visual feedback of the state of a process. It can be used to indicate if an
application is running, paused, or stopped. Lights are stacked one upon
another, up to five modules (standard unit contains three modules). Each
module is easily programmable without any special wiring or tools. An
Acoustic Alarm, Model 39303, is available as an option.
6085
Sensors Training System - This system contains a selection of

photoelectric, inductive, and capacitive sensors representative of what
can be found in industry. These sensors can be used with a variety of PLC
applications.
6410-A0
Portable Compressor - The Air Compressor consists of a quiet 7.6-liter

(two-gallon) air compressor. Its quiet pump and motor make it ideal for
classroom and school laboratories. The Air Compressor can be used to
provide compressed air to the Conditioning Unit, Model 6411-A.
6411-A0
Conditioning Unit - The Conditioning Unit consists of a main shutoff

valve, a filter, a pressure regulator, a pressure gauge, a sleeve valve,
and a muffler. It conditions and limits the pressure of the air supplied to
the pneumatic circuits. The Conditioning Unit must get its compressed
air from a central air supply or a portable unit such as the optional Air
Compressor, Model 6410-A.
Model
Number
Description
Push-Buttons/Lights
3202
Toggle Switch/Lights
3203
Rotary Switch
3204
Emergency Switch
3205
Wiring Module (two required)
3206
DC Power Supply Stepper

Motor
3207
Stepper Motor Drive
3208
Stepper Motor Drive Dual
3209
DC Motor Drive
3210
Optical Encoder
Opt
3213
Wind Generator
3214
Level Sensor
3215
Level Process Interface
3216
Pressure Regulator c/w gauge
3217
Station Control Valves
3291
Traffic Lights
3292
Electro-Pneumatic
3293
Electro-Mechanical DC Motor
3294
Electro-Mechanical Stepper
Motor
3295
Process Control
3296
Bottling Process
3297
Nacelle Simulator
5924
Signal Tower
6309
Storage/Work Surface
6411-A0
6424
Opt
Bottling
Process
Level
Process
Control
8075-1 8075-2 8075-3 8075-4 8075-5 8075-6
3201
6410-A
Wind
Turbine
ElectroMechanical
- Step
Motor
ElectroMechanical
- DC Motor
ElectroPneumatic
Traffic
Lights
Easy Reference Guide - PLC Applications and Components
8075-7
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
Opt
1
Opt
1
Opt
1
1
1
1
1
1
1
1
Opt
Opt
Opt
Opt
Portable Compressor
Opt
Opt
Conditioning Unit
Opt
Opt
Directional valve, single

solenoid
Opt = Optional equipment for advanced experimentation. (6410-A required if no alternate air source is available.)
P = Partial curriculum coverage only.
* = Requires corresponding Analog Expansion Kit (Model 3244-XX) to perform all exercises.
17
Model
Number
Description
8075-1 8075-2 8075-3 8075-4 8075-5 8075-6
Bottling
Process
Level
Process
Control
Wind Turbine
ElectroMechanical Step Motor
ElectroMechanical DC Motor
ElectroPneumatic
Traffic Lights
Easy Reference Guide - PLC Applications and Components
8075-7
PLC Compatibility
Allen Bradley MicroLogix 1100
Siemens ET200S (IM151-8)
3240-3
Allen-Bradley MicroLogix 1500
3240-4
3270-4
3270-6
Siemens S7-222
3240-A
3240-B\-C
P = Partial curriculum coverage only.

* = Requires corresponding Analog Expansion Kit (Model 3244-XX) to perform all exercises.
18
19
3240-A
24 VDC Outputs
Serial,
Ethernet
Communication
Ports
Fault Switches
3244-A
Built-in
Analog I/O
Expansion Kit
24V Power
Supply
Built-in
3244-B
Included
Ethernet
Cable
Step 7
5939
Built-in
3244-C
Included
Ethernet
Cable
Step 7
5939
MPI,
PROFINET
(Ethernet)
MPI,
PROFINET
(Ethernet)
120-240 V
50/60 Hz
12
ET200S
IM151-8
Siemens
3240-C
120-240 V
50/60 Hz
12
ET200S
IM151-8
Siemens
3240-B
3240-4
3270-4
12
Serial
120-240 V
50/60 Hz
10
14
MicroLogix
1200
Serial
24 VDC
10
MicroLogix
1000
Built-in
3244-3
Included
Serial Cable
with USB
converter
Built-in
3244-4
Included
Serial Cable
with USB
converter
6360
N/A
3246-4
RS Logix 500 RS Logix

RS Logix 500
3245-A*
500 3245-A*
3245-A*
Serial
120-240 V
50/60 Hz
12
12
MicroLogix
1500
Allen-Bradley Allen-Bradley Allen-Bradley
3240-3
6360
N/A
3246-3
Step 7
Micro/Win
3245-3
Peripheral
Port
24 VDC
SIMATIC
S7-222
Siemens
3270-6
5930-A
Built-in
TBE
Included
Ethernet
cable
Built-in
N/A
Included
Ethernet
cable
Built-in
N/A
Included
Ethernet
cable
Step 7
5939
3139
N/A
Included
Serial cable
EASYSOFT
Basic
(included)
Peripheral
Port
MPI,
PROFINET
(Ethernet),
PROFIBUS,
Serial
Serial,
Ethernet/IP,
DeviceNet,
SERCOS
24 VDC
2 voltage
inputs
EASY512
Moeller
3128-00
120-240 V
50/60 Hz
16
16
SIMATIC
S7-315T
Siemens
5930-B
120-240 V
50/60 Hz
16
16
RSLogix 5000 RSLogix 5000

Lite Edition
Lite Edition
5935*
5935*
Serial,
Ethernet/IP,
DeviceNet
120-240 V
50/60 Hz
16
16
CompactLogix CompactLogix
L32E
L43
Allen-Bradley Allen-Bradley
5930
TBE = To be established
*These model numbers are for educational institutions, such as high schools, accredited technical schools, and colleges or universities. These institutions must have
educational accreditation or affiliation status credentials and verifiable course syllabus and/or class agenda. Other types of customers (e.g., OEMs, end user companies, or
corporate training facilities) are excluded. For non-educational model numbers, contact your Lab-Volt Representative.
3246-4 or
included
Ethernet
cable
Programming
Cable
RS Logix
Programming
Software 500 3245-A*
Accessories
120-240 V
50/60 Hz
Power
Requirements
Analog I/O 2 voltage inputs
10
MicroLogix
1100
24 VDC Inputs
Processor
Manufacturer Allen-Bradley
Specifications
Easy Reference Guide - PLC Training Systems Specifications
Lab-Volt Systems, Inc.

Farmingdale, NJ 07727
USA
Phone: 732-938-2000
Fax: 732-774-8573
E-mail: us@labvolt.com
Lab-Volt Lte/Ltd.
Qubec (Qubec) G2N2K7
CANADA
Phone: 418-849-1000
Fax: 418-849-1666
E-mail: ca@labvolt.com
www.labvolt.com
1-800-LAB-VOLT
in the USA and Canada
85079-00 Rev. C1
20

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Programmable Logic

Controller (PLC) Guide

PLC Training Systems

PLC Training Systems

PLC Training Systems

PLC Training Systems

Various PLC Software Screen Images

PLC Training Systems

PLC Training Systems

Several communication networks (Ethernet IP,

PLC compatible with PROFINET and PROFIBUS networking

Shown with optional equipment

A well-known classic training system

Traffic light synchronization

N-S/E-W traffic control with pedestrian crossing

Another unit can be added to create a full, fourdirections traffic light

LEDs (long life)

Flow management with proximity detectors

Includes job sheets

Ten 24 VDC control inputs

Model 8075-2 Electro-Pneumatic System

Shown with optional equipment

solenoid valves (Accepts three 24 VDC control

Shown with optional equipment

Perforated base to accommodate optional sensors

Explores drives and lead screw positioning

Industrial 1800 RPM, 90 VDC motor

Accepts three 24 VDC control signals from PLC

Two magnetic limit switches for PLC feedback

Optional 100 ppr Optical Encoder

Model 8075-4 Electro-Mechanical System (Stepper Motor)

Shown with optional equipment

Two magnetic limit switches for PLC feedback

High-torque Stepper motor

Stepper motor drive programmed by computer

Perforated base to accommodate optional sensors

Programmable Stepper motor drive

Optional 100 PPR Optical Encoder

Motion sequences triggered by the PLC I/Os

Model 8075-6 Level Process Control System

Includes job sheets

Shown with optional equipment

Film canister capping process

Compact application combines pneumatics,

Perforated work surface

Two high-torque Stepper motors

Dual Stepper motor drive can be used as a Step/

Single solenoid directional valve

Easy Reference Guide PLC Compatibility

Flexible Manufacturing System

Model 5930-A: Allen-Bradley CompactLogix L43

Flexible Manufacturing System

Model 5930-B: Siemens SIMATIC S7-315T

Hydraulics and Pneumatics

Model 3270-4: Allen-Bradley MicroLogix 1000

Hydraulics and Pneumatics

Model 3270-6: Siemens SIMATIC S7-222

Model 3240-B: Siemens ET200S

Traffic Lights System